Method and structure for the manufacture of spring assemblies



NOV. 29, 1960 RYMLAND 2,961,667

METHOD AND STRUCTURE FOR THE. MANUFACTURE OF SPRING ASSEMBLIES Filed Jan. 15, 1957 2 Sheets-Sheet 1 '6 so 50 o 50 I6 4 26 FIG] 26 I8 2 20 re 22230 I8 20 22 20 I8 20 22 4 2O h I I6} 5 48 INVENTOR MURRAY J. RYMLAND ATTORNEYS Nov. 29, 1960 M. J. RYMLAND 2,961,667

METHOD AND STRUCTURE FOR THE MANUFACTURE OF SPRING ASSEMBLIES Filed Jan. 15, 1957 2 Sheets-Sheet 2 INVENTOR MURR AY J. RY M L A N D ATTORNEYS United States Patent C) METHOD AND STRUCTURE FOR THE MANU- FACTURE F SPRING ASSEMBLIES Murray J. Rymland, 2700 Hollius Ferry Road, Baltimore 30, Md.

Filed Jail. 15, 1957, Ser. No. 634,366

3 Claims. 01. -259) This invention relates to spring cushion assemblies and, more particularly, to a method and structure for interconnecting helical springs in predetermined spaced relationship to define the spring assembly.

A principal object of the invention is to provide an improved spring cushion assembly of inexpensive construction possessing desirable physical properties.

Another object is to provide a novel means facilitating the manufacture of spring cushion assemblies. A related more specific object resides in the provision of a novel clip and tie wire arrangement for frictionally engaging helical springs and retaining them in desired spaced relation in a spring cushion assembly.

A further object of the invention is to provide a novel method for facilitating the construction of spring cushion assemblies.

Other objects and advantages of the invention will become apparent from the following description and drawings in which:

Figure 1 is a fragmentary plan view of a spring cushion assembly embodying the invention;

Figure 2 is an elevational view of the assembly of Figure 1 with some of the portions thereof sectioned vertically such as on the line 22 of Figure 1;

Figure 3 is a fragmentary perspective view of the novel clip structure, shown in attached position; and

Figures 4-9 are fragmentary perspective views of a clip, the wires and springs, showing in sequence an exemplary embodiment of the novel method of assembling these parts.

Referring now to the drawings, a spring cushion assembly of the invention is illustrated in Figures 1 and 2 and comprises a plurality of component helical coil springs 12, constructed of flexible wire-like elements in any suitable manner. These springs 12 are arranged in predetermined, spaced relationship to define a plurality of parallel rows 14 and files 16, wherein the vertical axes of the springs are parallel. The springs 12 are shown to be of inverted, conical form, although it will be understood that springs of numerous other shapes or outlines such as hour glass or cylindrical, may be readily interconnected by the novel structure and method of the invention set forth hereinbelow.

To interconnect the springs 12 in desired space-d relationship, and to insure that the corresponding springs of adjacent rows 14 are properly ararnged and aligned with corresponding springs in the files 16, a plurality of tie wires 18 are disposed in parallel relationship to the horizontal center lines of the files 16, and additionally, a pair of such tie wires is utilized between adjacent files. Each tie wire 18, as best seen in Figure 3, preferably is provided with a plurality of pairs of spaced depressions 20, each pair being separated by an upwardly projecting insert portion 22, in the manner of the tie wire disclosed in my prior Patent No. 2,630,586. When positioned in the assembly, each pair of depressions 20 in each tie wire is fitted into embracing relationship with a corresponding arcuate portion 24 of the upper end convolutions 26 of suitable border structure.

a rectangular border wire 42 completely enclosing the the springs 12 in its respective file as seen in Figures 1 and 3. Each insert portion 22 of the tie wire will, accordingly, be disposed within its associated convolution arcuate portion 24 and preferably projects outwardly and upwardly therefrom.

The invention contemplates the employment of a novel clip 28 adapted to cooperate with the tie wire insert 22 and depression portions 20 as well as with the spring convolution arcuate portions 24 to fix and interconnect the springs 12 in spaced relation to define the rows 14 and files 16. A preferred embodiment of this clip 28, as best seen in Figures 2 and 3, includes a flat planar portion 30, reversely bent portions 32 at each end thereof defining an internal transverse channel 33 at said ends. The reversely bent portions 32 are joined to flat portions 34 deformed downwardly at their inner ends into depending portions 36. Portions 36 each define with the adjacent flat portion 34 an external transverse channel 38 parallel to the internal channel 33. Each depending portion 36' preferably is disposed approximately at right angles to the flat portion 34 and is joined at its lower end to an inwardly projecting tab 40 formed at right angles thereto and terminating in a free inner end as shown. These clips 28 preferably are of integral and fiat sheet metal construction of uniform transverse section configuration, of considerably greater width than thickness. The width of these clips is slightly less than the length of each tie wire insert portion 22 and the clip itself while being rcav, sonably stiff and rigid possesses some spring or resilient characteristics.

When connected to the springs 12 and tie wires 18 according to the preferred method of the invention to be set forth hereinbelow, the flat portion 30 of each clip 28 spans the transverse distance between adjacent tie wires 18 located between successive files 16, and is aligned with corresponding tie Wire insert portions 22. The insertv portions 22 are disposed in the clip internal channels 33, while the clip external channels 38 receive the convolution arcuate portions 24, and the tabs 40 are disposed below the arcuate portions 24, all as shown.

Each of the springs 12 is interconnected with adjacent springs in the same file and all files of springs are interconnected by the clips 28 and the tie wires 18, as indicated above and shown in Figure 1, to define a spring cushion assembly of desired size. The border regions of the spring assembly 10 may be reinforced by any One such structure includes assembly 10 and conveniently secured to the upper end convolutions 26 by a small helical spring 44. Spring 44 encircles wire 42 and may be coiled around the spring end convolutions 26, as shown.

The ends of the tie wires 18 may be looped around this border wire 42 or they may terminate somewhat short thereof as seen in Figure 1. It will be understood that in addition to its reinforcing purpose, the border wire 42 will retain the padding or filling material (not shown) in desired position in the fabric covered final product. In this regard, the portions of tie wires 18 between each pair of depressions 20 may be provided with horizontally disposed generally sinuous bends 46, as shown, tending to fill up the free space between adjacent springs 12, also for the purpose of retaining the padding material in position,

whereby the spacing of the springs may be economically increased without impairing the form retaining properties of the fabric covered product. that the length of the flat portion 31 of the clip can be readily increased or decreased for varying the spacing of the springs in the rows 14. The bends 46 in the tie wires permit some elongation or contraction of the length of the tie wires as is evident, and furthermore such bends may take numerous forms other than that shown.

It will be understood.

The bottom convolutions 48 of the springs may be interconnected by intersecting straps 50 running parallel to the rows 14 and the files 16 and frictionally interlaced with each other and with the bottom end convolutions 48 as seen in Figures 1 and 2. It will be appreciated, that if springs 12 are of cylindrical or hourglass configuration, the upper and lower end convolutions may be interconnected by clips 28 and tie wires 18 in the aforedescribed manner. The clip internal channels 33 and clip external channels 38 are so constructed and arranged that when associated with the tie wire insert portions 22 and arcuate convolution portions 24, as described above, they coact with the interconnection for the bottom convolutions 48 to form a lock with these parts involving forces that operate to retain the arcuate convolution portions 24 in tight frictional engagement with the associated tie wire in the regions of depressions 29. By virtue of the construction, there is no danger of separation or dislodgement of the springs from the tie wires. Moreover, these forces are of such magnitude due to the somewhat stiff spring characteristics of clip 28, that any undesirable relative movements between the springs 12 and tie wires 18 during normal use of the assembly will be effectively prevented.

The preferred method of the invention as illustrated in Figures 4-9, for interconnecting the springs 10 with the previously described structure will now be described. A first spring is arranged in upright position and a tie wire is engaged to the end convolution thereof by disposing the arcuate portion 24 in the spaced tie wire depressions 26 with the tie wire insert portion 22 extending upwardly and outwardly through the arcuate portion 24, as seen in Figure 4. The operator holds the spring and tie wire in this position with one hand and with the other hand takes one of the clips 28 and inserts the tab 40 thereof radially of the upper end convolution 26 between insert portion 22 and arcuate portion 24 from the inner end thereof into the position shown in Figure 4; then he slightly tilts or moves the clip 28 about its inner or right end in a clockwise direction as indicated by arrow A and simultaneously applies an outward force to the inner end of the clip in the general direction of arrow B; whereby the clip depending portion 36 will be snapped through the space between the insert portion 22 and the arcuate portion 24. The clip will now be in the general position shown in Figure 5, or some other inclined position between the horizontal and vertical dispositions thereof illustrated in Figures 4 and 5. With this snap-like movement of the clip depending portion 36, the tie wire insert portion 22 enters the adjacent clip internal channel 33 and the adjacent clip external channel 38 receives the arcuate portion 24-. The clip is now swung in the direction of arrow C back to the horizontal position shown in Figure 6. This completes the interconnection of the first spring with the first tie wire.

At this time another spring, hereinafter referred to as the second spring, is positioned by the operator in alignment with the first spring (see Figure 7) to form the first row and another tie wire, hereinafter referred to as the second tie wire, is engaged to the end convolution of the second spring in the same manner as that described for the first tie wire and first spring. The next step in the process preferably involves holding the first spring, first tie wire and clip in one hand and the second spring and second tie wire in the other hand, and aligning the second tie wire insert portion with the already connected first tie wire insert portion. Then, while maintaining the relative axial or longitudinal positions of the two tie wires sta tionary, the second tie wire insert portion or the clip, or both, are moved so that the adjacent or second tab 40 of the clip enters the space between the second tie wire insert portion, as shown in Figure 7. It may be necessary in the adjacent clip depending portion 36 abuts the insert portion 22 and the second spring arcuate portion 24 until this step to swing the closest portion of the convolution of 4 the second spring slightly downwardly away from the first spring as in the direction of arrow B.

At this time the operator swings the partially attached end of clip 28 relatively downwardly and outwardly with respect to the second spring in the direction of arrow D and simultaneously swings the end convolution of the second spring upwardly, if desired. This enables the ad jacent clip depending portion 36 to be forced or snapped through the space between the tie wire insert portion and second spring arcuate portion 24 (see Figure 8). This snap movement of depending portion 36 for both springs is actually accompanied by an audible, snap sound indicating to the operator that desired engagement has been effected. After the clip has been attached to the second spring and tie wire, the second spring end convolution is.

allowed to return to its normal position by movement in the direction of arrow F, whereby the second tie wire insert portion will be disposed in the adjacent clip internal channel 33 and the second arcuate portion 24 will be disposed in the adjacent clip external channel 38, as shown in Figures 2 and 9.

Other springs will be similarly interconnected by additional clips with the remaining insert and depression portions of the first and second tie wire to form adjacent files and rows (see Figure l). Thereafter, additional files of springs will be formed in similar manner until the desired length and width of the spring assembly is achieved.

It will be appreciated that the bottom spring convolu-- tions may be interconnected before or after the upper end convolutions are joined together by the wires and clips. This is possible since the amount of spring movement necessary for effecting the desired connections is relatively small and could be effected even though the bottom convolutions had been previously joined; and also because the frictional engagement of the clip with the tie wires and springs is effective to hold them in desired position throughout the entire assembly even though the bottom convolutions may not be joined until after all or some of the upper end convolutions had been joined.

An outstanding feature of the invention is the configuration at the ends of clip 28. As seen in Figure 2, the clip in the regions of external channels 38 is in engagement with or contacts less than one half of the periphery of a radial cross section through that part of the wirelike element in the engaged arcuate portion 24 of the spring end convolution 26. This relatively small contact area has been found to be satisfactory to retain the parts in assembled position, and it greatly facilitates the assembly operations inasmuch as the tabs 40 may be disposed adjacent the fiat portion 34 for convenient insertion between the tie wire insert and the spring end convolution. The clips will also be effective to retain the spring arcuate portions 24 firmly in engagement with the tie wire depressions 20, without requiring a clinching or like operation on the clips. In this regard, it will be evident that compression of the springs 12 will not impair this lock, and the clip in turn will desirably transmit individual loads or forces throughout the assembly 10 without interfering with spring compression.

If desired, the portions of the tie wires between inserts 22 may be straight and undeformed, omitting depressions 20 and bends 46.

It will thus be seen that the objects of this invention have been fully and effectively carried out. It will be realized, however, that the embodiments described and illustrated for the purpose of disclosing the principles of the invention may be changed without departing from such principles. Therefore, this invention embraces all modifications encompassed by the spirit and scope of the following claims.

I claim:

1. In a spring cushion assembly, a pair of similar helical springs constructed of flexible wire-like elements and arranged in spaced parallel relation, means interconnecting said springs including: a pair of spaced parallel tie 'wires intersecting and engaging as chords associated and adjacent arcuate portions of the upper end convolutions of the springs, each of said tie wires including an offset insert portion disposed within its associated convolution arcuate portion; and a preformed clip extending between said convolution arcuate portions and having an internal and an external channel formed at each end thereof, each of said offset insert portions being disposed in one of said channels and the adjacent convolution arcuate portions being disposed in the other channels.

2. The structure defined in claim 1 wherein said clip is constructed of sheet metal having a much greater width than thickness, and further wherein said ofiset insert portions are disposed in said internal channels of said clip while said adjacent convolution arcuate portions are disposed in said external channels.

3. A method of interconnecting helical springs in spaced relation by means of pairs of spaced tie wires and preformed clips wherein said tie wires include spaced ofiset insert portions and each of the clips includes pairs of spaced internal and external channels, said method comprising: fitting an ofiset insert portion of a first tie wire within an arcuate portion of an end convolution of a first spring with said first tie wire intersecting said end convolution as a chord; attaching the clip to the first spring with the tie wire oifset insert portion being disposed in an internal channel of the clip and the convolution arcuate portion being disposed in an adjacent external channel of the clip; disposing a second tie wire parallel to and spaced from the first tie wire, fitting an offset insert portion of the second tie wire within an arcuate portion of an end convolution of a second spring adjacent to said first-named arcuate portion and in alignment with the first-named tie wire insert portion, with said second tie wire intersecting said end convolution of said second spring as a chord, holding said tie wires axially stationary relative to each other and simultaneously fitting the secend-named tie wire offset insert portion into the other internal channel and fitting the second spring arcuate portion into the other external channel.

References Cited in the file of this patent UNITED STATES PATENTS 630,968 Brouyette Aug. 15, 1899 765,258 Steinhofl July 19, 1904 1,473,989 Holtfoth Nov. 13, 1923- 1,746,942 Hise Feb. 11, 1930 2,184,517 Duvall et al Dec. 26, 1939 2,242,919 Nachman May 20, 1941 2,351,659 Bronstein June 20, 1944 2,383,157 Pink Aug. 21, 1945 2,630,586 Rymland Mar. 10, 1953 

